Customized electronic displays and methods of customizing the physical size and/or shape thereof

ABSTRACT

Electronic displays are physically reshaped and/or resized to meet custom specifications for special applications such as avionics, where Commercial Off-The-Shelf (COTS) Liquid Crystal Displays (LCDs) are not typically used. Customization includes cutting the physical display to specified dimensions to fit into a target opening, and resealing the display to preserve proper cell spacing and assure basic functionality. The sealing process may include improving the original seal, and/or providing additional seals.

RELATED APPLICATION DATA

This application is a continuation of application Ser. No. 10/888,151,filed Jul. 9, 2004, issuing as U.S. Pat. No. 7,535,547 on May 19, 2009,which is a continuation of Ser. No. 10/103,473, filed Mar. 20, 2002, nowU.S. Pat. No. 7,525,633, issued Apr. 29, 2009, which is a continuationof Ser. No. 09/812,370, filed Mar. 16, 2001, now U.S. Pat. No. 6,380,999issued Apr. 30, 2002, which is a continuation of application Ser. No.09/274,427, filed Mar. 22, 1999, now U.S. Pat. No. 6,204,906 issued Mar.20, 2001.

FIELD OF THE INVENTION

The present invention relates generally to electronic displays, and moreparticularly to the customization of an original display by physicalalteration of the size and/or shape thereof, such that the customizeddisplay may be used in installations not considered achievable with theoriginal display.

DEFINITIONS

In this application, COTS is used as an acronym for “CommercialOff-The-Shelf”; FPD is used as an acronym for “Flat-Panel Display”; LCDis used as an acronym for “Liquid Crystal Display”; PDLC is used as anacronym for “Polymer-Dispersed Liquid Crystal”, AMLCD is used as anacronym for “Active Matrix Liquid Crystal Display”; TAB is used as anacronym for “Tape-Automated-Bonding”; COG is used as an acronym for“Chip-On-Glass”; UV is used as an acronym for “ultraviolet”, VLSI isused as an acronym for “Very Large Scale Integration”, and HDTV is usedas an acronym for “High-Definition Television”. All of these terms arewell-known in the art.

BACKGROUND

Electronic displays are commonly used to portray data in the forms ofvisual text and/or other images, so the data may be interpreted and/oracted upon. Typically, the operator of equipment associated with thedisplay will control the equipment based in part on the interpretationof the data displayed. A simple example is an airplane pilot who views acontrol panel display representing surrounding air traffic, and who thencontrols the airplane to avoid the traffic.

The displays and their associated bezels (face plates) and frames(interfacing and supporting hardware) are typically built to demandingspecifications for durability, reliability, and operating life, due toindustry requirements, and the resulting displays have relativelycomplex electrical, chemical, optical, and physical characteristics.Each particular application, for example, may require specificperformance characteristics from the display, such as the ability toaccommodate or withstand varying conditions of temperature, humidity,radiation, ambient light, shock, vibration, impact, chemicals, saltspray, water and fluid condensation, immersion, or other environmental,electrical, physical, and/or other conditions. Due to the high costsassociated with such varying and demanding specifications, for anyparticular application it is thus economically necessary formanufacturers to produce a common design in high production volume,resulting in COTS displays all having substantially the samecharacteristics for a variety of physical sizes. The sizes vary, but theshapes are generally rectangular with an aspect ratio of approximatelythree to four. Common television and computer displays typically have anaspect ratio of approximately three to four, and are typically square.HDTV displays typically have an aspect ratio of nine to sixteen.

For specialized applications where the market may not be large enoughfor COTS manufacturers to enter, buyers of displays are required to havedisplays custom-built to fit their size and shape requirements, at acost up to ten times greater than the cost of a COTS display havingidentical functionality. Alternatively, buyers may choose to incorporatea COTS display into an existing control panel or dashboard opening byphysically altering the size and/or shape of the control panel openingto match the size and/or shape of the COTS display. For mostapplications, however, such modifications cannot be made withoutdisturbing the surrounding instruments, controls, and displays alreadyincorporated into the control panel. Such is the case, for example, onan airplane control panel or other vehicle control panel where largenumbers of instruments and controls are tightly and efficiently packedinto a relatively small area to begin with. And even if the appropriatemodifications could be made, they are typically cost-prohibitive.

To overcome the above-referenced drawbacks in the prior art, it wouldthus be desirable to provide systems and methods for customizing a COTSdisplay to meet the size and shape requirements of a target controlpanel opening, such that the purchaser of the COTS display may avoidpaying the extra costs associated with having a display custom-builtfrom scratch. Such systems and methods would be advantageous fordisplays that have relatively high tooling costs and relatively lowvolume production associated therewith.

A particular industry where high-cost custom-built displays are used isthe avionics industry, which traditionally used square panel openings tohouse mechanical control devices. To retrofit airplane control panelswith electronic displays, the industry began manufacturing squaredisplays, at a relatively high cost and relatively low volume comparedto the COTS non-square displays which are commercially used in a widevariety of applications. In fact, the control panels in newly-builtairplanes designed to use electronic displays, are still often made withsquare panel openings, despite the COTS displays being non-square, inorder to maintain the well-established and familiar control panelconfigurations.

Since a completed electronic display is delicate and relatively complex,most experts in the filed would not expect that customization of thedisplays as desired could be accomplished by physically cutting anoriginal display, changing its size and/or shape, and resealing it,while maintaining its same basic functionality. For example, mostexperts would not expect that a display designed to be a four-inch bysix-inch display with 480 rows by 640 columns of picture elements(pixels) could be cut down to the size of a four-inch by four-inchdisplay with 480 rows by 480 columns, and still operate successfully.

SUMMARY OF THE INVENTION

Typically, a COTS display comprises two plates, front and back, holdingdrive electronics on the edges. The plates are typically glass orplastic, and may have polarizers, filters, image enhancement films,and/or viewing angle enhancement films attached thereto. Row and columnorthogonal electric leads distributed throughout an image-generatingmedium are contained between the plates, and a perimeter seal holds theplates together while isolating and protecting the image-generatingmedium from the outside environment. The row and column electric leadstranscend the seal to external leads to which electronic drivers areattached. The electronic drivers are typically VLSI circuits bonded toTAB substrates attached to the display, or directly attached to thedisplay as COG. In some instances the VLSI electronic drivers are madein-situ with the display picture elements.

The present invention involves systems and methods for customizing aCOTS display by modifying the physical size and/or shape of the COTSdisplay to meet the requirements of a target application. This isaccomplished by cutting the physical COTS display to reduce its physicalsize and/or shape, and then resealing the display to achieve the desiredperformance. The basic functionality of the COTS display remains intact.That is, the customized display will have a new size and/or shape, andmay have altered electronic drivers, image-generating media, rearrangedelectronics, additional seals, additional films, etc., and may actuallyhave enhanced functionality. However, the customized display will beable to operate in a target application designed to interface with adisplay of the same type (e.g., AMLCD) as the original (e.g., COTS)display.

When the plates are cut, internal electronics might also be cut, oftenrequiring reestablishment of electrical continuity. Similarly, thedisplay electronics may be removed, reattached, or otherwise modified,and filters, polarizers, and/or other films associated with the displayand typically attached externally to the plates may be cut, to conformto the customized display size and/or shape. Thus the opportunity existsto add enhanced functionality to the display. A custom bezel and framemay then be used to house the display, allowing for additionalruggedization of the entire unit.

To reseal the display, an adhesive is applied along at least the cutedge or edges. A second seal may be added to minimize the penetration ofhumidity and other contaminants into the display media (e.g., liquidcrystal material) inside the display cell. A third seal serving as amask may also be applied to prevent back light typically used with LCDsfrom passing through the display around the outer edges of the displayimage area.

Electronic drivers, typically VLSI circuits (bonded to TAB substratesattached to the display, or attached directly to the display as COG) maybe added, repositioned and/or reattached as needed, and the circuitry onthe display plates may be altered to make electrical connection to thenew VLSI circuits. Filters, films, polarizers, etc., may then be cutand/or installed as desired, and additional components such as heaters,optical elements, infrared filters, touch panels, transducers, etc., maybe added to alter and/or enhance durability or functionality of thedisplay.

Finally, the reshaped and/or resized, and/or otherwise altered displayis placed in a custom bezel and frame with appropriate ruggedizationcharacteristics. The bezel and frame are designed to accommodate thenewly sized and/or shaped display in a suitable manner, and to allow forproper mechanical and electrical attachment to the target location, suchas an avionics box or display panel. The bezel and frame also areconfigured for installation such that appropriate lighting, opticalelements, transducers, heaters, infrared filters, touch panels, etc.,associated with the target application operate properly. The frame thusprotects the display and interfaces the display with the targetlocation, such as an avionics box or display panel. Suitable adhesives,sealants, conformal coatings, potting compounds, electrical and thermalconductors, screws, clamps, rivets, connectors, gaskets, etc., may beused as necessary or desired to further ruggedize the unit and installit into its target location. Ruggedization may be required, for example,before installing the customized unit into environments of vehicles,ships, submersibles, missiles, aircraft, spacecraft, portable equipment,etc., which tend to be more restrictive and severe than the environmentsfor which COTS displays are designed. Similarly, simulators forsituations such as those described above may also require ruggedizationof the customized unit.

One aspect of the present invention thus involves customizing anelectronic display by cutting the display along desired dimensionsresulting in a target display portion and an excess display portion, andapplying a first seal between the plates along an exposed edge of thetarget display portion, said first seal creating a barrier to preventthe image-generating medium from escaping out of the area between theplates, wherein the basic functionality of the display remains intact. Asecond seal and/or a third seal may be added.

Another aspect involves customizing an electronic display by cutting thedisplay along desired dimensions resulting in a target display portionand an excess display portion, applying a first seal along an exposededge of the target display portion between the plates, applying a secondseal over the first seal, and applying a third seal over the secondseal, wherein the basic functionality of the display remains intact.

Another aspect of the present invention involves creating a customizedelectronic display comprising a substantially flat front plate having anupper surface and a lower surface, a substantially flat back platehaving an upper surface and a lower surface, said back plate positionedbehind said front plate and substantially parallel thereto, a perimeterseal positioned between said plates and forming an enclosed cell areadefined by the lower surface of the front plate, the upper surface ofthe back plate, and the perimeter seal, an image-generating mediumcontained within said cell area, electrical conductors distributedthroughout said image-generating medium, a substantially flat firstpolarizer attached to the upper surface of said front plate, said firstpolarizer having a perimeter, a second seal positioned over theperimeter seal, and a first silicone bead positioned over the perimeterof the first polarizer. A third seal may be added.

Systems and methods are thus described for customizing an original (e.g.COTS AMLCD) display to meet the size and/or shape requirements of atarget location. Other objects and advantages of the present inventionwill be apparent from the detailed description which follows, when readin conjunction with the associated drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a plan view of a typical COTS AMLCD.

FIG. 1B is a cross-sectional view of FIG. 1A, along line 1B-1B, with thecolumn TABs removed from the cross-section for purposes of clarity.

FIG. 2A is a plan view of a customized display made from the COTS AMLCDshown in FIG. 1A, by cutting along line 2-2 in FIG. 1, and thenresealing.

FIG. 2B is a cross-sectional view, along line 2B-2B, of the customizeddisplay shown in FIG. 2A, with the column TABs removed from thecross-section for purposes of clarity.

FIG. 3 is a plan view of a customized display, showing additionalspecial cuts that might be required as part of the customization.

FIG. 4A is a partial cross-sectional view of a customized display havingstaggered cuts on the opposing plates, showing first and second seallayers.

FIG. 4B is a partial cross-sectional view of a customized display havingaligned cuts on the opposing plates, showing a third seal layer.

FIG. 4C is a partial cross-sectional view of a customized display havingan extended lower plate for use to attach electronic drivers or jumperwires.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1A and 1B show a typical rectangular, non-square COTS AMLCD 10,before resizing and/or reshaping, but after disassembly from itsoriginal bezel, frame, and other associated hardware and electronics.The external components associated with the display 10 other than thecircuit boards 15 and the components bonded or attached to the displayplates 20 f and 20 b, have been removed for clarity. Such externalcomponents would preferably be removed prior to performing thecustomization of the display 10 as described herein.

The display 10 comprises a front plate 20 f and a back plate 20 b, eachpreferably made of glass or plastic. The plates 20 are held together bya perimeter seal 25 such as a UV curing urethane as is known in the art,and are also typically further secured within a bezel (not shown) whichis in turn secured to a frame or other hardware (not shown) forattachment to the target location. Polarizing films 30 f and 30 b,filters (not shown), image enhancement films (not shown), retardationfilms (not shown), viewing angle enhancement films (not shown), and/orother films may exist on the front and/or back outer surfaces of theplates 20. The original display image area 40 defined by themanufacturer of the COTS AMLCD is indicated by dashed perimeter line 45.(Dashed line 50 represents the desired right edge of the display imagearea 40 after customization, as will be described shortly). Alight-blocking mask (not shown) is typically placed between plates 20and covers a perimeter area form the outer edge of the display imagearea 40, and extending outwardly to a sufficient distance to serve itspurpose. Typically, the distance will be up to the edge of the bezel, orto the inner edge 55 of perimeter seal 25 as indicated by arrows 60 inFIG. 1A. Without the mask, light escaping around the edge of the displayimage area 40 might cause distraction to a person viewing the display10.

Row and column electronic drivers 65 r and 65 c respectively are bondedto TAB substrates 70 r and 70 c respectively, which in turn are bondedto the edges of the plates 20 using electrically-anisotropic adhesives75 as is known in the art. In avionics, bent TABs (not shown) are oftenused to save panel area. In addition or alternatively, the drivers 65may be attached directly to the plates 20 as COGs. The electronicdrivers 65 are preferably at least VLSI circuits, having correspondingexternal leads 80 r, 80 c electrically connected through perimeter seal25 to the row and column electric leads 85 r, 85 c respectively (seeFIG. 2A). For simplicity, only a few leads 80 from only one row TAB 70 rand two column TABs 70 c are shown in FIG. 2A, but it is to beunderstood that each row TAB 70 r and each column TAB 70 c may havedozens or even hundreds of individual leads 80 as is known in the art.The row and column electric leads 85 are distributed throughout animage-generating medium such as liquid crystal material (normallytransparent) contained between the plates 20, as seen in FIG. 2A. Theperimeter seal 25, in addition to holding the plates 20 together,isolates and protects the image-generating medium from the outsideenvironment. The TABs 70 are bonded or soldered to circuit boards 15,and are electrically connected to external sources via connections 90 tocircuit boards 15, and as is well known in the art. COGs (not shown) maybe electrically connected to the edges of the display plates 20 whichare connected electrically via ribbon cables to external sources, as isknown in the art. Again, for simplicity only a few connections 90 areshown in FIG. 2A, but it is to be understood that they may be providedas desired or needed.

To customize the COTS AMLCD 10 of FIG. 1A, an example will be describedwherein the display 10 (and circuit boards 15) are cut along line 2-2 inFIG. 1 to reshape the display 10 to fit into a square target panelopening, such as that of an airplane control panel. The resultingcustomized display 10′ is shown in FIGS. 2A and 2B. The customization ofa COTS display 10 may be done in varying degrees, as necessary ordesired, and the examples provided herein are not to be viewed assetting forth required techniques unless specifically so stated.

The COTS display 10 is preferably first mounted into a fixture (notshown) to stabilize the display 10 in preparation for cutting. Thefixture may also be used to maintain cell thickness (the distancebetween the plates 20) and desired dimensions. Part or all of thefixture may be the VPI FAST-24 model glass-cutting machine made by VillaPrecision International, Phoenix Ariz.

The display 10 is then cut to its desired shape along the desireddimensions, which in our example is a square. The cut or cuts may beperformed in a single step, by laser cutting, sawing, grinding, etc., orin multiple steps wherein the first step is a tracing or preparatorystep. For example, the desired dimensions might first be scribed,etched, traced, etc., and the display 10 may then be broken along thescribe dimensions. Any method sufficient to ensure a substantiallysmooth cut is acceptable. Scribing with a precision glass-cuttingmachine with vacuum-holding and optical alignment capability has beenshown to be sufficient. AMLCDs are typically made with a borosilicatehard glass and approximately 60 pounds of pressure has been shown to besufficient for scribing the glass. The scribe wheel is preferably madeof diamond or is of a hard carbide type. A small wheel (e.g., 1 mm to 4mm in diameter) with a sharp angle (e.g., approximately 100 degrees) hasbeen shown to be sufficient, at a nominal cutting speed. Each plate 20should be scribed separately. The optical alignment feature of themachine is helpful to ensure that the corresponding scribe lines onopposing plates 20 f and 20 b are coincident or displaced as desired.Alignment marks placed on COTS displays by manufacturers may be used foralignment in the glass-cutting machine.

Circuit boards 15 may also be cut by techniques known in the art, asindicated by cut-line 2-2, as can TABs 70. However, if a dimension linecalls for cutting through an electronic driver 65, the driver may needto be relocated and/or replaced. If polarizers 30 or other films arepresent, it is possible to cut them simultaneously while cutting theplates 20, but it is preferable that they are scored first to create atarget polarizer portion for further use in the customization process,and an excess polarizer portion that may be discarded. The excesspolarizer portions are then removed prior to cutting the plates 20.Doing so allows unobstructed access to the plates 20 for cutting theplates 20. After scoring the films, simple peeling away of the unwantedportions has been shown to be sufficient.

Thus, the specific dimensions of the score lines to remove the filmsshould be selected to substantially correspond to the target cuttingdimensions, but be offset radially inward a slight amount. The goal isto allow the original films to remain intact over the target displayimage area 40′ while still providing unobstructed access to the plates20 for cutting the plates 20. For example, in FIG. 1A, the targetdisplay image area 40′ is defined by the square A-B-C-D, and the targetcutting line for the plates 20 is shown as line 2-2. The target scoreline for the polarizers 30 and other films present might be line 95.After scoring, all portions of the films to the right of line 95 will bepeeled away. Similar procedures would be used for each display plate 20f, 20 b. That will leave sufficient leeway 100 between the targetcutting line 2-2 for the plates 20, and the newly-exposed edge (definedby line 95) of the polarizers 30 and films. Additionally, the remainingportions of the original polarizers 30 and films will still cover thetarget display image area 40.

Immediately, or soon after the display 10 is cut (either by directcutting or by scribing and breaking, for example), the display 10 isoriented to prevent the liquid crystal material or otherimage-generating medium from escaping due to any newly-exposed unsealededges. Precision glass-breaking machines are available from VillaPrecision International, Phoenix Ariz. Manual breaking, after scribing,by one skilled in the art, merely using hands and fingers, has beenfound to be sufficient. After breaking, a simple manual re-orientationof the display 10′ has been shown to be sufficiently timely. Typically,the image-generating medium is not viscous enough to escape. The excessdisplay portion (105 in FIG. 1A), may be discarded, while the targetdisplay portion (110 in FIG. 1A) is retained for further customization.

The newly-exposed plate edges are then cleaned and wiped dry of anyexcess liquid crystal material using, for example, a dry cotton swab.Care should be taken to not use fluids, as fluids might contaminate theliquid crystal material. Liquid crystal material is then drained orwicked out of the cell to allow for a replacement seal line 115 to beplaced along the then newly-exposed and newly-unsealed plate edges. Thereplacement seal 115 is installed by applying an adhesive along the cutedge and preferably in between the plates 20 to reseal the display 10.′The adhesive is preferably chosen to have proper mechanical propertiesto preserve the cell spacing. For example, precision micro-spheres maybe mixed into the adhesive to ensure spacing. The adhesive should alsohave a proper viscosity to allow it to flow inwardly sufficiently tofill any void in the cell between the plates 20 and the liquid crystalmaterial. Low-viscosity UV curing urethane of the methacrylate familyhave been shown to have the desired characteristics. A wetting and/orthinning agent may be used as needed. In addition, these urethanesinterface with the liquid crystal material without adverse effects, asis well-known in the field of PDLCs. Curing time of approximately fiveminutes has been shown to be sufficient.

The adhesive and display 10′ may need to be outgased to remove anytrapped gases and voids, as the adhesive is being cured. Both theoutgassing and the curing may be accomplished by techniques well-knownin the art. After curing, a second seal 120 is preferably added, thenoutgased and cured as necessary. A UV curing lamp(s) and/or heater(s)may be mounted in a vacuum chamber for ease in outgassing and curing.The second seal 120 is preferably silicone, and is applied to minimizethe penetration of humidity and contaminants into the liquid crystalmaterial inside the cell. The silicone seal 120 is preferably thermallyset, as is known in the art. The silicone seal 120 may have black ink,dye, or pigment added thereto to produce a substantially black-coloredsilicone, and may be applied up to the outer perimeter of the targetdisplay image area 40,′ to prevent back light from passing through thedisplay 10′ around the outer edges of the target display image area 40.′

Alternatively, an optional mask or third seal 125 may be added to thenewly-exposed plate edges over the silicone seal 120, and applied up tothe outer perimeter of the target display image area 40.′ The mask 125is shown partially broken away in FIG. 2A. It should be dark (preferablyblack), and may be tape, ink, sealant, adhesive, plastic, or any othersuitable material. At least one of the dark silicone seal 120, or theoptional mask 125, are preferred, to replace any of the original mask(not shown) removed during the customization process. Additionally, themask 125 may be placed around the entire perimeter of the cell,substantially overlaying the original perimeter seal 25 and originalmask.

If internal electronics 85 are cut, electrical continuity may need to bereestablished as will be described shortly. Similarly, new VLSI circuits65 may be needed, or the dimension lines may intersect a TAB 70 or COGlocation (see FIG. 3 for example), and therefore the TABs 70 or COGswould be removed and reattached with the same or new VLSI circuits 65 bytechniques used in the industry for repairing displays. Theconfiguration of the TABs 70 and/or COGs may be changed to accommodatesize and packaging requirements. The circuitry on the display plates 20may be altered to make electrical connection to the new VLSI circuits.The COG circuits may be changed to TABs 70, and vice versa. The TABsubstrate 70 itself may be changed to bent tabs, for example, toaccommodate new packaging requirements.

If it is desired to replace the liquid crystal material, the materialmay be extracted and replaced with another image-generating medium, toenhance or alter performance. If the extraction is to be done first,then only a single break in the seal 25 is needed to drain or suck outthe original material. However, two breaks in the seal 25 may beused—one to apply pressure and the other to apply suction for extractionof the material. With two breaks, the new image-generating medium may bepumped or fed into the pressure end concurrently with the suction on theother end, thus allowing the new image-generating medium to displace theold material in a single process. Other techniques are known in theindustry for refilling the cell.

Thus, additional modifications and/or enhancements that may be made tothe display during reshaping and/or resizing include relocating, adding,and/or removing, TABs 70 or COGs; replacing electric circuits and/orsupplementing with circuits having different functionality; alteringand/or replacing the display medium; and/or adding, removing, and/orreplacing polarizers, filters, and/or films.

Turning now to FIG. 3, a display 10′ with additional special cuts 130,135, and 140, for a custom avionics application is shown. In thisexample, the corners 150 and 155 are to be removed to allow for theprotrusion of screws and other mechanical and electrical objects fromthe target control panel, and one edge 160 is to be trimmed as indicatedby cut-line 140. Additionally, circular cuts 145 f and 145 b arerequired for protrusion of a shaft or other object such as a mechanicalindicator. The circuit boards 15, seals 25, and most of the TABs 70 havebeen removed for clarity of the drawing. In this example, one of thedimension lines 140 requires a cut through the present location of a TAB70, such that the TAB 70 may need to be removed and reattached, eitherbefore or after cutting.

The row and/or column leads (85 r and 85 c respectively) are exposed atpoints 165 by a staggered cut of the plates 20, and may be cleaned andprepared as is known in the art, prior to being connected to a TAB 70 orCOG. The techniques previously described may be used for the specialcuts 130, 135, 140, and 145. However, as exemplified by the circularcuts 145, this example shows a situation wherein the electricalcontinuity of the row and/or column leads (85 r and 85 c respectively)will need to be reestablished.

The proper electrical connections may be reestablished using a jumperwire which reconnects the broken leads by traversing a path outside ofthe display image area 40.′ For example, one such path is along theexposed portion of a plate 20 from one end of the plate 20 to the other(see 170 in FIG. 3). Another such path may be through the circularcutouts (see 145 in FIG. 3), where there may be an exposed surfaceportion 175 on the back plate 20 b due to staggered cutting (e.g., thecircular cutout 145 f on the front plate 20 f may have a larger diameterthan the circular cutout 145 b on the back plate 20 b, as seen in FIG.3). Alternatively, the conductive paths may be mounted on or integratedwithin the under surface of the mechanical indicator to be placed withinthe circular cutouts 145. This may be accomplished using, e.g., a wire,a polyimide tape circuit with anisotropic conductive adhesive, or acircuit board with appropriate electrical connectors.

For desired dimensions such as the circular cutout, some amount of theimage-generating medium may escape at virtually any orientation of thedisplay 10′ due to gravity. Keeping the plates 20 substantially flat,however, should minimize such escape, due to surface tension between theimage-generating medium and the plates 20, as well as due to the lowviscosity of the image-generating medium. Any escaped material, however,may be replaced using techniques described herein and/or known in theart. The exposed edges of the plates 20 due to the circular cutout areas145 should be sealed using the techniques described herein.

Turning now to FIGS. 4A, 4B, and 4C, various sealing techniques will bedescribed in more detail. Each of these drawings shows a partialcross-section of a customized display 10,′ from a similar perspective asin FIGS. 1B and 2B, and like FIGS. 1B and 2B, the column TABs 70 c havebeen removed for clarity.

The display 10′ may be cut to various pre-sealing arrangements, some ofwhich are shown in FIGS. 4A, 4B, and 4C. The staggered cut, shown inFIG. 4A, provides an extra exposed surface 180 on the back plate 20 b tosupport the second seal 120, and the second seal 120 will generally bestronger as compared to the second seal 120 on an evenly cut set ofplates 20 as shown in FIG. 4B. Though neither the second seal 120 northe third seal (the light mask 125) are required, they are bothpreferred.

The first seal 115 is an adhesive and serves the purpose of barricadingthe image-generating medium from leaking out, as well as mechanicallyholding the plates 20 together at the proper spacing. By way of example,the cell gap (space between the plates 20) for AMLCDs is typically 6micrometers with tolerances of 0.1 micrometers. Glass beads, or suitableobjects, may be added to the seal material to aid in preserving theminimum cell thickness. The adhesive must be chemically compatible withthe image-generating medium. The compatibility, reacting and mixing ofurethanes, epoxies, and water emulsions, with liquid crystal materials,have been studied extensively in the field of PDLC displays. TheUV-curing adhesives used to repair automobile glass cracks would besuitable here as the environmental conditions may be similar.

The second seal is a silicone adhesive and serves the purpose of ahumidity and moisture barrier. A family of silicone encapsulants andadhesives has been developed for the electronics industry to preventhumidity and moisture from attacking electronic parts. As used with themethods described herein, the use of silicone is designed primarily tokeep water molecules away from the liquid crystal material, polarizers,and display electronics. Silicones such as Sylgard brand by Dow CorningCorporation, part numbers 527 and 184, may be used. The humidity andmoisture protecting properties of silicone are well-known in theelectronics packaging industry.

As a further ruggedizing measure, a silicone seal or bead 185 (similarto the second seal 120) may be applied along all cut edges, or alledges, of the polarizers 30 and other films, as seen in FIGS. 4A, 4B,and 4C. For example, when submitted to avionics temperature/humiditytesting, the polarizers 30 deteriorated at the edges. These seals 185would further protect the polarizers 30 from such damage. In fact, toruggedize a COTS display 10 for avionics use, all permeable seam linesand areas sensitive to moisture may be covered with silicone seals. Inparticular, the polarizer edges, the liquid crystal cell seal 25,plastic electronics packages, and any exposed conductors or metalelectrodes may need to be covered. The silicone has the effect ofoccupying all chemically active sites and cross-linking to inhibit watermolecules from accumulating in the silicone and at the silicone surfaceinterface being protected. Additionally, silicone is used to suppresscorona discharge and electrostatic detrimental effect on, around, andnear conductors.

These additional silicone seals may be applied at any time during theprocess, but it is preferred that they are applied after the COTSdisplay 10 is cut and the first seal 115 has been reapplied. It shouldbe done then because silicone chemically attaches to most surfaces andis not easily removed by conventional chemicals or cleaning agents or bysurface cleaning techniques. Also, once cured, the silicone is notreadily bonded to by other materials. This includes the body of thesilicone, as well as any surface the silicone wetted, even after removalby conventional techniques. Because of the unique properties of siliconeadhesives and sealants, they should be used sparingly and appropriatelyby a person skilled in the art of sealants or silicone use. Conformalcoatings, such as polyimide, may also be used to cover the exposedelectric leads and provide additional protection thereto.

A third seal or mask 125 may also be used to prevent back light frompassing through the display 10′ around the outer edges of the targetdisplay image area 40.′ Typically, a COTS display 10 has a black mask inthe plane of the image or image-generating medium. The third seal 125should be applied to the top and bottom of the plates 20, up to the edgeof the target display image area 40′ (best seen in FIG. 2A), to trap thelight and prevent its escape due to parallax between the plates. Opaquelayers in varying degrees of opacity may be used. Alternatively or inaddition, black absorbing dyes or pigments may be included in the firstseal 115 and/or second seal 120.

Other seals may be added to further enhance the sealing, ruggedizationand performance of the completed display unit. For example, a thermalconductive perimeter seal may be added to conduct heat to or from thedisplay 10.′ An additional adhesive layer, such as polysulfide, may beused to bond the display glass cell to a metal frame. Conformal coatingssuch as polyimide may be used to ruggedize various parts.

FIG. 4C shows a cutting arrangement resulting in an extended bottomplate area 190, which may be used to attach TABs 70 or COGs or jumperwires as desired.

The basic functionality of the original display remains intact. That is,the customized display may have a new size and/or shape, and may havealtered electronic drivers, image-generating medium, rearrangedelectronics, additional seals, additional films, etc., and may actuallyhave enhanced functionality. However, the customized display will beable to operate in a target application designed to interface with adisplay of the same type as the original display. For example, a COTSAMLCD, having gone through a customization process as described herein,will be able to function in an avionics application designed tointerface with an AMLCD. The customized display would respondappropriately to electrical signals designed to be input to the COTSdisplay. Pixels on the customized display would continue to operate asthey would in connection with the COTS display. The speed of response,contrast ratio, gray shades, etc., of the customized display wouldoperate as they would in connection with the COTS display. The ultimateimage (text, graphics, pictures, etc.) would thus appear appropriatelyon the display image area of the customized display.

While certain embodiments are illustrated in the drawings and aredescribed herein, including preferred embodiments, it will be apparentto those skilled in the art that the specific embodiments describedherein may be modified without departing from the inventive conceptsdescribed.

For example, depending upon the specific requirements for a particularapplication, various combinations of the customizing techniquesdescribed herein may be applied. The seals 115, 120, 125, and 185, maybe applied in different combinations, different amounts or ratios, andvarying sequences, depending on the application. Some of the seals maybe omitted or used redundantly as the application may require.

Additionally, though the examples used herein generally referred to COTSAMLCDs as used in avionics where square displays are used, the conceptsare equally applicable to other types of LCDs or other displaytechnologies, and for other industrial applications including thoserequiring other customized shapes. Furthermore, though the examples usedshow only one set of row TABs and two sets of column TABS, in practicethat may be switched, or there may be two sets of each, and the quantityof each may vary, all as is desired or needed for a specificapplication.

Accordingly, the invention is not to be restricted except by the claimswhich follow.

1. A method for changing the physical shape of an electronic display,wherein the display comprises a front plate, a back plate, electricalcircuits on inner surfaces of the plates for operating an originaldisplay image area of the display, a perimeter seal spacing apart theplates, and image-generating medium sealed in an area between the platesand within the borders of the perimeter seal, the method comprising:mounting the display in a fixture to maintain cell thickness; cuttingthe display along desired dimensions resulting in a target displayportion and an excess display portion, thereby breaking the perimeterseal, cutting at least some of the electrical circuits, and creating anexposed edge along the target display portion that extends from a firstside edge of the display to a second side edge of the display; removingimage-generating medium from the area between the plates along theexposed edge; applying an adhesive along the exposed edge, the adhesiveflowing into the area between the plates; and curing the adhesive tocreate a first seal between the plates along the exposed edge.
 2. Themethod of claim 1, wherein the first seal is disposed within the areabetween the plates such that the first seal contacts inner surfaces ofthe front and back plates.
 3. The method of claim 1, wherein theadhesive comprises a low-viscosity adhesive capable of flowing inwardlyinto the area between the plates to fill any void between the platesalong the exposed edge.
 4. The method of claim 1, further comprisingoutgassing the electronic display after applying the adhesive to removetrapped gases from the area between the plates.
 5. The method of claim1, wherein the image-generating medium is removed to create a void inthe area between the plates, and wherein the adhesive flows into thearea between the plates to fill the void when the adhesive is appliedalong the exposed edge.
 6. The method of claim 1, further comprisingapplying a second humidity seal along the exposed edge over the firstseal.
 7. The method of claim 6, further comprising a third masking sealover the second seal for preventing back light from passing through theexposed edge.
 8. The method of claim 1, wherein the display is cut by:scribing the front and back plates along scribe dimensions; and breakingthe front and back plates along the scribe dimensions.
 9. The method ofclaim 1, wherein the adhesive is cured by exposure to ultraviolet light.10. A method for changing the physical shape of an electronic display,wherein the display comprises front and back plates, a perimeter sealspacing apart the plates and at least partially defining an enclosedcell area between the plates that comprises an original display imagearea, image-generating medium contained in the area between the platesand within the borders of the perimeter seal, and electrical circuits oninner surfaces of the plates extending through the original displayimage area, the method comprising: cutting the display along desireddimensions that extend across the original display image area resultingin a target display portion and an excess display portion, therebybreaking the perimeter seal, cutting at least some of the electricalcircuits, and exposing an edge of the target display portion; applyingan adhesive along the exposed edge, the adhesive flowing in between theplates; and curing the adhesive to create a first seal between theplates along the exposed edge.
 11. The method of claim 10, wherein theadhesive comprises a low-viscosity adhesive capable of flowing inwardlybetween the plates to fill any void between the plates along the exposededge.
 12. The method of claim 10, further comprising outgassing theelectronic display after the step of applying the adhesive to removetrapped gases and voids from between the plates.
 13. The method of claim10, further comprising applying a second humidity seal along the exposededge over the first seal.
 14. The method of claim 13, further comprisinga third masking seal over the second seal for preventing back light frompassing through the exposed edge.
 15. The method of claim 10, whereinthe display is cut by: scribing the front and back plates along scribedimensions with a scribe wheel; and breaking the front and back platesalong the scribe dimensions.
 16. The method of claim 10, wherein theadhesive is cured by exposure to ultraviolet light.
 17. A method forchanging the physical shape of an electronic display, wherein thedisplay comprises front and back plates, a perimeter seal spacing apartthe plates, image-generating medium contained in an area between theplates and within the borders of the perimeter seal that comprises anoriginal display image area, the method comprising: cutting the displayalong desired dimensions intersecting the original display image arearesulting in a target display portion and an excess display portion,thereby breaking the perimeter seal and exposing an edge of the targetdisplay portion that extends from a first side edge of the display to asecond opposite side edge of the display, the target display portioncomprising a target display image area that is smaller than the originaldisplay image area; and applying an adhesive that flows in between theplates along the exposed edge, the adhesive creating a first seal toprevent the image-generating medium from escaping out of the areabetween the plates.
 18. The method of claim 17, further comprisingmounting the display in a fixture to maintain cell thickness beforecutting the display.
 19. The method of claim 17, wherein the adhesivecomprises a low-viscosity adhesive capable of flowing inwardly betweenthe plates to fill any void between the plates along the exposed edge.20. The method of claim 1, wherein the display comprises externalcircuit boards extending along edges of the display, the method furthercomprising cutting the circuit boards.
 21. The method of claim 1,wherein the display defines an enclosed cell area between the platesthat comprises the original display image area, and wherein the desireddimensions intersect across the original display image area such thatthe target display portion comprises a target display image area that issmaller than the original display image area.
 22. The method of claim21, wherein the original display image area has a rectangular shape, andwherein the display is cut such that the target display image area issquare.
 23. The method of claim 10, wherein the first seal is disposedwithin the area between the plates such that the first seal contactsinner surfaces of the front and back plates.
 24. The method of claim 10,wherein the display comprises external circuit boards extending alongedges of the display, the method further comprising cutting the circuitboards.
 25. The method of claim 10, wherein the display defines anenclosed cell area between the plates that comprises the originaldisplay image area, and wherein the desired dimensions intersect acrossthe original display image area such that the target display portioncomprises a target display image area that is smaller than the originaldisplay image area.
 26. The method of claim 25, wherein the originaldisplay image area has a rectangular shape, and wherein the display iscut such that the target display image area is square.
 27. the method ofclaim 17, wherein the adhesive comprises a flowable material that flowsbetween the plates to contact inner surfaces of the front and backplates, the method further comprising curing the adhesive between theplates to create the first seal.
 28. The method of claim 17, wherein thedisplay comprises a polarizer on at least one of the plates, and whereinthe polarizer is cut when the respective plate is cut.
 29. The method ofclaim 17, wherein the display comprises a polarizer on at least one ofthe plates, the method further comprising removing at least a portion ofthe polarizer before cutting the display.
 30. A method for customizingthe physical shape of an electronic display, wherein the displaycomprises front and back plates, a perimeter seal spacing apart theplates and at least partially defining an enclosed cell area between theplates that comprises an original display image area having arectangular shape, image-generating medium sealed in the area betweenthe plates and within the borders of the perimeter seal, and electricalcircuits on inner surfaces of the plates extending through the originaldisplay image area, the method comprising: cutting the display alongdesired dimensions that intersect across the original display image arearesulting in a target display portion and an excess display portion,thereby breaking the perimeter seal, cutting at least some of theelectrical circuits, and exposing an edge of the target display portionthat extends from a first side edge of the display to an opposite secondside edge of the display, the target display portion comprising a targetdisplay image area that is smaller than the original display image area;applying an adhesive such that the adhesive is located between theplates along the exposed edge of the target display portion, theadhesive creating a first seal to reseal the area between the plates andprevent the image-generating medium from escaping out of the areabetween the plates of the target display image area.
 31. The method ofclaim 30, wherein applying the adhesive comprises moving theimage-generating medium between the plates of the target display portionalong the exposed edge to accommodate the adhesive flowing between theplates.
 32. The method of claim 31, wherein moving the image-generatingmedium comprises removing image-generating medium from between theplates along the exposed edge.
 33. The method of claim 31, wherein theimage-generating medium is moved by draining the image-generating mediumfrom between the plates along the exposed edge.
 34. The method of claim31, wherein the image-generating medium is moved by wicking theimage-generating medium from between the plates along the exposed edge.35. The method of claim 30, wherein the display comprises externalcircuit boards extending along edges of the display, the method furthercomprising cutting the circuit boards.
 36. The method of claim 30,wherein the original display image area has a rectangular shape, andwherein the display is cut such that the target display image area issquare.
 37. The method of claim 30, wherein the first seal is disposedwithin the area between the plates such that the first seal contactsinner surfaces of the front and back plates.
 38. The method of claim 30,wherein the display comprises a polarizer on at least one of the plates,and wherein the polarizer is cut when the respective plate is cut. 39.The method of claim 30, wherein the display comprises a polarizer on atleast one of the plates, the method further comprising removing at leasta portion of the polarizer before cutting the display.